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The functional design of a pavement relates to the selection of appropriate wearing course materials which optimise the trafficability of a pavement. Trafficability is dictated to a large degree by the choice, application and maintenance of locally available wearing course materials. Poor functional performance results in decreased safety and operational efficiency and increasing road and vehicle maintenance requirements. An optimal functional design will include a certain amount and frequency of maintenance (watering, grading etc.) and thus maintenance itself can be planned, scheduled and optimized within the limits of required road performance and minimum vehicle operating and road maintenance costs. Since no wearing course material selection guidelines, tailored to the specific needs of surface mines, were available, there was the need to identify appropriate selection guidelines for the range of materials commonly encountered for road building on South African mines. The aim of this paper is to present an overview of the functional design method for mine haul roads and, through an analysis and quantification of existing wearing course material performance, to recommend appropriate wearing course material selection guidelines. The functional design technique has been applied at a number of mines and is illustrated by an application case study which demonstrates the potential reduction in total transportation operating costs associated with the optimal functional design.

Jan 1, 2000

By G. J. de Korte

Dense-medium beneficiation of fine (minus 0.5 mm) coal is not a new concept and has been used in South Africa previously. The dense-medium fine coal plant at Greenside Colliery operated for almost 18 years and, despite proving a difficult plant to operate, did succeed in producing a fine coal product with a low ash content of 7%. No other beneficiation process available could achieve this. Dense-medium beneficiation of fine coal was also used in other countries, of which the plants at Homer City in the USA and Curragh in Australia were the best known. The first application of dense-medium cleaning of fine coal was, however, at the Tertre plant in Belgium1. This plant was built in 1957. About nine years later, a second fine coal dense-medium plant was built at the Winterslag Mine, also in Belgium. According to reports, this plant operated satisfactorily for a period of some 17 years.

Jan 1, 2002

By J. He

The separation performance of a raw coal sample from South Africa based on the dense gas-solid fluidized bed beneficiation technique was investigated. Analysis showed that the raw coal sample distributes mainly in the -50+6 mm size range with the -1.6 g/cm3 density fraction accounting for 78.20% of the cumulative mass distribution. A flow sheet of the sequential coal beneficiation technique was introduced. The experimental and simulation results of the hydromechanical and density distribution stability indicate that the dense gas-solid fluidized bed could provide a stable separation environment with uniform density fluctuations under suitable operating conditions. With the application of this technique on the raw coal sample, the separation results show that three products, consisting of 73.25% clean coal with an ash content of 9.59%, 11.31% middlings, and 15.44% gangue were effectively separated at two different densities of 1.82 g/cm3 and 1.57 g/cm3. This study provides an effective flow sheet for achieving the high-efficiency separation performance on raw coal from arid areas. Keywords dense gas-solid fluidized bed, dry coal beneficiation, density distribution, separation efficiency.

Jul 1, 2013

By M. W. Hildyard

The aim of this paper is to demonstrate that active seismic measurements could have an impact in helping solve rock engineering problems experienced in the South African mining industry. The paper presents a variety of experimental and numerical results where seismic waves show clear differences in wave-speed and amplitudes due to different degrees of fracturing. It presents results from the ?Omnibus? project commissioned to develop new ultrasonic technologies for diagnosing fracturing for nuclear waste repositories. This included using models to investigate assemblies of cracks where the effects of crack density and crack size on waveforms are shown to be coupled. Results indicate that these effects can be decoupled in the frequency domain, where the Fourier amplitude aids in estimating crack size, while the low frequency phase-difference has a direct relationship to crack density. Models are also shown to aid interpretation of waveforms by isolating geometric effects from the effects due to cracks. Two rock engineering problems experienced in the South African mining industry are investigated through numerical examples. These demonstrate that determining whether ?crush? pillars have failed and determining the degree of fracturing in the hangingwall of stopes, may be possible through the use of active seismic surveys.

Jan 1, 2005

By W. Mbhalati

"Conzal Mine was not meeting production targets in 2013, and it was established that this was caused by the inability of the load haul dump machines (LHDs) to tram the required tonnages. An investigation of the LHD productivity was therefore conducted to identify the inhibiting factors. This was accomplished by carrying out a literature review on LHD operations to gain in-depth knowledge and conducting observations in the working environment. The relevant information and data on the LHD type used at Conzal was also acquired.The major inhibitor was found to be excessively long tramming distances in all the sections of the mine. The one-way tramming distances were all significantly greater than the 90 m set in the mine’s code of practice (COP), with the Main Shafts section having the longest average one-way tramming distance of 260 m. The other inhibitor was LHD utilization, which in 2013 was only 47% against a target of 70%. Simulation of the LHD operation, taking these two factors into account, showed that production could be increased by more than 100%. As a result, it was recommended that conveyor belts should be extended regularly in order to keep tramming distances within the recommended one-way distance of 90 m. In addition, utilization can be improved by minimizing employee absenteeism as well as by modifying the travelling routes such that LHDs do not encounter unnecessary delays.Paper written on project work carried out in partial fulfilment of BSc. (Mining Engineering)"

Jan 1, 2015

By L. A. Cramer

Platinum metal was first utilized by the Inca civilization in South America where it was found in alluvial deposits along the San Juan and Atrato rivers that lie between the Andean mountain range in Colombia and the Pacific Ocean. The nuggets found in these rivers average between 77% and 86%platinum, 7%?8% iron and small amounts of copper, gold and other Platinum Group Metals (PGMs). The Incas often alloyed platinum with copper to increase its workability and fabricated various ornaments from it. With the arrival of the Spanish in the early 1700s, platinum was labelled a nuisance for the Spanish in their quest for alluvial gold because it concentrated with the gold and had to be removed by either extended amalgamation or by hand sorting. It was at this time that platinum received the root of its current name for the Spanish referred to it as platina del Pinto, platina being the somewhat derogatory diminutive of plata (silver). Pinto was a river in Colombia where the Spanish first distinguished it. The English eventually adopted ?platina? and it is only in recent times that the Latin name platinum has been accepted as the metal?s common English name. From its first introduction to European scientists in 1740, platinum was unappreciated because of its brittle nature and difficulty of working and as a result had little commercial value. Its ability to be dissolved in gold did lead to some counterfeiting of gold bullion and even to the debasement of gold currency.

Jan 1, 2000

By Jerry Gagnon, Matt Burr, Dave Evans, Timothy Ellis, Davies Kakengela, Abbas Mirza, Larry Webb, François Leclercq, Andrew Johnston

Lead-based alloys are the primary anodes used in electrowinning from sulphate-based aqueous systems. Lead anode technology has evolved over the years, migrating from pure lead and lead-antimonial alloys to the present day lead-calcium-tin alloys for copper electrowinning and lead-silver alloys for zinc electrowinning. It has also migrated from cast to rolled microstructures in search of improved mechanical properties and higher corrosion resistance. Although great strides have been made in the development of new alloys and production processes, the industry still has unresolved issues related to untimely corrosion which limits anode life and may lead to higher contaminant levels in the metal being produced. Lead anodes corrode because of the difference in the chemical/electrochemical potential across the microstructural features of an anode. Given a very high purity material, we find that the grain boundary areas corrode significantly faster than the rest of the grain. The desire to minimize grain boundary corrosion by a balance of alloying element selection and microstructural design allows the grain boundary area to be engineered. However, operational issues can lead to unexpected corrosion behaviours which we will discuss moving forward. The comments in this work, though directed toward copper electrowinning, can be extended to similar phenomena in other metals electrowon from sulphate media (i.e., zinc, nickel, cobalt, manganese). The lifecycle of electrowinning anodes is dependent upon electrowinning tankhouse operating conditions and maintenance of the anodes, including cleaning and straightening. This paper will focus on the operational aspects of maximizing the utilization of lead electrowinning anodes.

Jan 1, 2015

By Q. P. Campbell

The high final total moisture content of fine coal after mining and processing is one of the major reasons that this resource is not extensively used in subsequent power generation, combustion, or other conversion processes. Some coal products, like export coal, may be subjected to a variety of environmental conditions during transport and storage, such as temperature and humidity. To understand the mechanisms by which moisture is attracted and held on and within fine coal particles, further information is needed regarding the processes occurring at the coal surface. In order to determine the correlation between physical coal properties and its moisture adsorption and desorption characteristics, a series of sorption experiments were conducted on various coal samples under climatically controlled conditions. Equilibrium moisture data was collected while changing the temperature and humidity. This data was correlated to coal properties such as particle size, porosity, maceral composition, and mineral content. All the coals that were studied were medium-rank bituminous coals. It was found that the best predictors for moisture adsorption and desorption were the mineral and inertinite contents. Keywords moisture, adsorption, desorption, fine coal, surface properties.

Nov 1, 2013

By G. M. Dowo

The widespread environmental damage caused by slimes dam construction requires rehabilitation as one of the key management strategies towards land restoration. From the time when Mhangura Copper Mine in Zimbabwe was shut down in 2000 due to viability problems, no follow-up studies were carried out on the slimes dams to assess their development with respect to ecosystem function and longterm recovery. The ecosystem function analysis (EFA) method was thus employed to achieve this end. EFA is a monitoring procedure that establishes how well an ecosystem functions as a biophysical system through the use of rapidly assessed field indicators. The field procedure makes use of simple visual indicators that are related to various soil surface processes. Conventional sampling methods are used to collect the vegetation data. The data was first analysed using landscape function analysis (LFA) software packages and then with various multivariate statistical techniques. In total 27 species were recorded from 14 families; 21 of them occurring in the acacia woodland and only 8 on the slimes dams. Hyparrhenia sp. was the dominant grass on Dam 5 and Imperata cylindrica dominated Dam 6. Acacia saligna was the most abundant tree species on the dams. The tree layer on the slimes dams was not as developed as the grass layer. The rehabilitated slimes dams converged with the natural woodland for the LFA indices of stability, nutrient cycling, and infiltration, which suggested a high level of functionality. The main factors affecting the sustainability of the rehabilitation are postulated to be fire, grazing, and tree harvesting. The study contributed to the importance of, and methods used for, assessing ecosystem function on rehabilitated slimes dams in Zimbabwe, which are often ignored as most efforts focus on the establishment of vegetation on the dams. Keywords ecosystem function analysis, EFA, mine tailings, rehabilitation, monitoring, Mhangura Copper Mine, ecosystem function.

Dec 1, 2013

By M. L. Bakker

The ISASMELT? top submerged lance (TSL) bath smelting process was developed in Mount Isa, Australia by Mount Isa Mines Limited (now a subsidiary of Xstrata plc) during the 1980s. By the end of 2011, the total installed capacity of the ISASMELT? technology will exceed 8 000 000 metric tons per year of feed materials in copper and lead smelters around the world. Commercial plants, operating in Belgium and Germany, are also batch converting copper materials in ISASMELT? furnaces. This TSL technology is equally effective for continuous converting processes, in which role it is called ISACONVERT?. This paper presents the recently patented ISACONVERT? process for the continuous converting of nickel and platinum group metal (PGM) containing mattes using the calcium ferrite slag system. The paper focuses on the potential application of the ISACONVERT? technology to existing nickel and PGM smelting complexes.

Jan 1, 2011

Mine wide, underground wireless communications are possible with the use of Ultra Low Frequency (ULF) technology. Due to the propagation through rock of ULF radio signals a relatively small antenna can provide communications coverage over a complete mining operation. Starting as a Personal Emergency Device (PED) for emergency messaging to miners under all circumstances, the ULF communications system has grown to include capabilities of remote control of underground equipment such as pumps and fans and centralised blasting initiation. This technology is now in use on 5 continents having lately made it onto the African mining scene. The paper and presentation will provide the audience with the benefit from international mining know-how in this technology as well as local African experiences. A recent commissioning exercise for example, is expected to pay for itself in electricity savings within a few months. These and other results from practical demonstrations and usage will be covered. This novel technology becomes an integral part of the daily operating infrastructure of a mine with immediate safety and business benefits. It is able to reduce capital expenditure and is designed for ease of routine operational use. The paper will conclude with insights into current R&D for further development of this technology.

Jan 1, 2007

Assuming that a gold ore has been effectively ground to ensure maximum economic liberation of gold, the circuits that will have the most effect on the successful operation of a gold plant will be that of the leaching and carbon-in-pulp circuit (CIP). The reagent and utilities operating costs associated with leaching, adsorption, elution and regeneration would typically make up some 15% of total operating cost, whilst the capital costs associated with these areas is about 16% of the total. Although not largest (capital and operating costs associated with comminution are generally dominant) these items represent a significant proportion of capital and operating cost. Much more importantly, these plant areas represent the primary gold recovery process and their technical and operational efficiencies will have a significant impact on overall plant efficiency. The objective during process design of these sections is thus to develop a design which provides maximum technical and economic efficiency and which is robust to potential changes in ore throughput, mineralogical characteristics and head-grade. Experience has shown that, particularly for longer life and higher-grade projects typical of the South African underground gold mining industry, small changes in recovery and efficiency have a significant value over the life of the project.

Jan 1, 1999

By W. H. Van Niekerk

The metal zinc has been around since only about 1400 AD. This may sound like a long time, but when compared to fellow base metals copper and lead, which were discovered in 5000 and 4000 BC respectively, it is evident that zinc is a fairly new kid on the block. This may also be the reason why many new facts and benefits of zinc are still being discovered. For instance, it has been discovered only in the last few decades that virtually no life on earth is possible without zinc. In this address it will be shown that zinc is not only very useful to mankind, but is in fact vitally important for all forms of life. It will be shown that zinc is natural, zinc is essential for life, zinc protects, zinc contributes to the well-being of society and that zinc is fully recyclable. It is therefore hoped, that by the end of this address, zinc will no longer be viewed only as the metal that is responsible for the nice colour of roofing sheets and steel buckets, but may indeed be man?s best friend.

Jan 1, 2005

By L. W. Burger

The need to establish and harmonise methodologies to quantify air emissions, atmospheric dispersion and the consequences of air pollutants (especially hexavalent chromium) from the ferrochrome industry became important aspects with the increasing demands for comprehensive impact assessments. The paper includes a synthesis of current knowledge on the following aspects: ? Locally and internationally accepted methodologies for the quantification of chromium emissions, including sampling methods and emission factors; ? A compilation of recognised and accepted air quality sampling and laboratory analysing techniques; and, ? Dispersion modelling and impact assessment tools. Depositing and removing materials from the chromium ore stockpile and wind erosion of exposed stockpiles result in mainly chromite emissions unlikely to contain significant amounts of hexavalent chromium. Pre-treatment processes such as drying, crushing and screening also produces chromium emissions, but mainly as trivalent chromium. The smelting of chromium is the major source of chromium emissions - open furnaces have the highest uncontrolled chromium emissions, followed by semi-closed and closed furnaces, respectively. Based on the current knowledge on emission rates, interim emission factors for particulate, total chromium and hexavalent chromium releases are provided. Ambient sampling and analytical methods to determine environmental exposure of the general public require that hexavalent chromium needs to be quantified in very low concentrations. Suggested sampling and analytical methods for both source characterisation and ambient monitoring are provided. The selection between dispersion models needs to be based on the size of the modelling domain and the complexity of the terrain. The discussion on dispersion models includes the US EPA?s Industrial Source Complex Model (Version 3), the AERMET/AERMOD suite of models and the CALMET/CALPUFF suite of models. Guidelines are also proposed for environmental exposure assessments including cancer and non-cancer health effects.

Jan 1, 2004

By I. A. Mwamba

Titanium sponge, which is almost pure titanium, is extremely ductile and not easily processed into titanium powder. One method of producing powder is the hydride-dehydride (HDH) process, where titanium sponge is hydrided to form brittle titanium hydride (TiH2). Titanium hydride is easily milled to produce powder and is then dehydrided to form Ti powder. In this work, titanium hydride powder obtained from titanium sponge was used as a starting material for blending and mechanical alloying with elemental powders. Firstly, titanium hydride powder was blended with aluminium elemental powder to produce a homogenized powder, which was then compacted and sintered to produce powder metallurgy compacts. Secondly, titanium hydride powder was mechanically alloyed with aluminium elemental powder and then compacted. The mechanically alloyed powder was characterized in terms of particle size distribution, morphology and microstructure. In both blending and mechanical alloying, the green compacts were characterized by assessing the green density, while the sintered compacts were characterized by their sintered density, microstructure, and hardness. The two processes have resulted in the formation of TiA13 intermetallic compound. It was established that by simple mixing and homogenizing, titanium hydride can be used as a starting material to produce powder metallurgy components in which porosity is a benefit rather than a problem, much akin to metallic foams. From the products obtained in the TiHz-Al system, it appears that titanium hydride can be used as a precursor in mechanical alloying. However, the possible formation of complex hydrides may introduce detrimental properties, and needs to be further investigated. For the production of non-porous components, it would be advisable to dehydrogenate the TiH2 powder before milling i.e. producing titanium powder by the hydride-dehydride (HDH) method. Keywords Mechanical alloying, titanium hydride, titanium aluminide and blending

Jan 1, 2011

By F. J. Plaul

The dominating technologies for steelmaking are the basic oxygen furnace (BOF or LD process, Linz-Donawitz) and the electric-arc furnace (EAF). The main iron input materials for both are liquid iron as hot metal, or solid iron as pig iron, DRI (direct reduced iron), HBI (hot briquetted iron) and scrap. Hot metal, pig iron (i.e., solidified hot metal) and DRI/HBI are virgin iron materials, which have to be produced from iron ore by so-called ironmaking technologies. The family of ironmaking technologies includes three process routes: blast furnace, smelting reduction and direct reduction. Driven by steadily increasing costs of raw materials in the last two decades, the sector has seen a number of new developments in ironmaking technologies, developments based on fluidized-bed technology. The main advantage of a fluidized-bed technology is that fine iron ore can be directly charged to the process without prior treatment; it does away with agglomeration and its concomitant cost, a step practised in blast-furnace, COREX® and MIDREX® processes. With Posco of South Korea, Siemens VAI Metals Technologies has successfully developed the FINEX® process, a smelting reduction based on the direct use of iron ore fines to produce hot metal. The key technology is the four-stage, bubbling fluidized-bed-reactor system, in which fine iron ore is reduced to DRI fines in a countercurrent flow with a reducing gas generated by coal gasification. Beside surveying the current state of the art, this paper discusses the technological principles of smelting-reduction and direct-reduction processes. The status of FINEX® and the outlook for further developments are described. Crucial to the successful development of the new ironmaking technologies for the direct use of fine ore was the scaling up of the fluidized-bed reactor system, which demonstrated new design features.

Jan 1, 2009

By C. Hutton

"SynopsisThe last commodities supercycle (2003 to 2011) was characterized by a belief in volume at any cost, where absolute output was deliberately prioritized over productivity considerations. This practice fuelled overoptimistic forecasting and planning, which in turn contributed to the economic crisis that followed. The sudden collapse of commodity prices has resulted in mining companies scrambling to find the right balance between optimizing current operations and preserving sufficient flexibility to grasp future opportunities. The runaway costs of building and operating mines have almost squeezed out profit margins, while lower ore grades are inflating production costs. Mining companies therefore need to look at the business with fresh eyes, and develop strategies to attract equity capital as traditional approaches are simply not working anymore. This is especially so in the context of a dwindling investor base that continues to demand greater returns, despite a significantly lower appetite for risk. This paper revisits the micro-economic concepts and demonstrates how pressure from shareholders to prioritize output contributed to spiralling costs and value destruction. Practical techniques are described to model cost curves to optimize a Mineral Resource endowment and address the need to rightbalance a business and preserve agility.IntroductionHenry Lazenby (2014) for the Mining Weekly writes, ‘Bruised and battered, the global mining industry today is undergoing a sea change. Practices and policies that might have worked wonders in the past are not as relevant today, and new approaches to running profitable mining operations need to be found.’ One significant practice the mining industry had during the last commodities supercycle (2003 to 2011) was chasing volume at any cost; absolute output was deliberately prioritized over productivity considerations (Goldsmith, 2013). Lazenby contends that in the face of falling and volatile commodity prices, many mining majors ‘across all commodity groups are currently grappling with sagging profits and low company valuations. This is often regarded as the result of the were in pursuit of growing their output at all costs in a high commodity price environment.’ Lee Hodgkinson, KPMG’s Canadian mining industry leader and quoted by Lazenby, says that ‘mining companies are now trying to find the right balance between optimizing current operations and preserving their agility to grasp future opportunities. The runaway costs of building and operating mines have almost squeezed out profit margins [whilst] lower grades of ore are inflating production costs. Mining companies need to look at the business with fresh eyes, and develop strategies to attract equity capital as it seems clear that some of the traditional approaches to the mining business are simply not working anymore."

Jan 1, 2015

Often plant performance suffers as a result of poor control. Poor control leads to low mill throughputs, poor classification and less than satisfactory concentrate grades and overall recoveries. By using the appropriate control tools, substantial gains in plant performance can be made. Mintek?s MillStar and FloatStar controllers have been implemented at various sites across the world. The MillStar controller incorporates leading technology that controls process units from the mill feed through to the flotation feed. Typical results show that milling circuit throughput is increased by 6-10 % and the final product grind size is tightly controlled, thereby enhancing flotation performance. The FloatStar controller is aimed at stabilising and optimising flotation circuits. Through improved level control alone, recovery improvements of up to 1 % have been achieved. Furthermore, by using on-line grade analysers, the controller stabilises final concentrate grades, whilst maximising flotation recovery.

Jan 1, 2005

By M. H. Solomon

After the global financial crisis of 2008, African mining is entering anew phase of development. The rapid withdrawal of emerging market funding from the critical exploration and development industries provided a hiatus in funding, a gap which was quickly filled by Chinese and other Asian investors. While the continent is still economically dependent on its extractive industries, the prevalence of Dutch Disease has undermined Africa?s ability to benefit fully from its mining, oil, and gas industries. While the extractive industries are closely related to many of the more fragile and failed states in Africa, it is equally true that the strongest states in Africa have mining-based economies. This paper explores the possible linkages between mining, strong and weak political economies, and poverty in Africa. It draws the conclusion that neither Dutch Disease nor Resource Course is a given in resource-endowed countries, and that it can be avoided if the mining economies in these countries are actively integrated into their respective broader economies and used to foster economic diversification. The author asserts that given the capacity constraints of many African governments, it is contingent on mining companies to become integrally involved in catalysing diversification around their infrastructure and supply chains.

Jan 1, 2011

By J. T. Nel

Non-transfer-arc linear plasma systems are highly suited to manufacturing nanoparticles. In this paper, the manufacturing of such particles with specially designed plasma systems is discussed. In general, it entails the volatilization of a metal halide that is injected in the high-temperature region of a plasma flame, where it is reacted with a suitable reagent, for example O2, to produce nanooxide powders. Metal powders can also be introduced directly in the plasma. Due to the very short residence time of only milliseconds in the reaction zone, as well as the fact that the reaction takes place in the gas phase, combined with very rapid quenching in the order of 10 000°C.s-1, nanoparticles are produced. At Necsa the manufacturing of such particles has been demonstrated on various scales. A pilot plant for the production of nano-Al2O3, and two pilot plants, one using SiCl4 and the other one using SiF4 as feed material, were built to produce fumed, pyrogenic, nano-SiO2. The alumina plant had a production rate of 8?10 kg.h-1 and the silica plants had production rates of 2 and 10 kg.h-1 respectively. Perfectly spherical alumina particles with a particle size distribution of between 10 and 200 nm were produced on a continuous system. Particle size analysis for the silica by SEM measurements showed a d50 of 60 nm and a particle size distribution of 30?100 nm. The specific surface area was in the range of 170m2.g-1. Other samples of plasma produced nanoparticles such ZnO and B4C will also be presented.

Jan 1, 2010